Hyperelastic shape setting devices and fabrication methods

ABSTRACT

Shape-setting methods for fabricating devices made of single crystal shape memory alloys. In particular the methods described may be used to fabricate dental arches of single-crystal shape memory alloys. The methods include drawing a single crystal of a shape memory alloy from a melt of the alloy. This is followed by heating, forming, and quenching the crystal sufficiently rapid to limit the formation of alloy precipitates to an amount which retains hyperelastic composition and properties of the crystal.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority as a continuation-in-part of pendingU.S. patent application Ser. No. 11/949,663, filed on Dec. 3, 2007, andtitled “HYPERELASTIC SHAPE SETTING DEVICES AND FABRICATION METHODS,” nowU.S. Pat. No. 7,842,143.

INCORPORATION BY REFERENCE

All publications and patent applications mentioned in this specificationare herein incorporated by reference in their entirety to the sameextent as if each individual publication or patent application wasspecifically and individually indicated to be incorporated by reference.

FIELD OF THE INVENTION

This invention relates to mechanical devices that have a component inwhich large recoverable distortions are available in extruded shapes.

BACKGROUND OF THE INVENTION

Common shape memory alloy (also called SMA) materials such as Nitinolcan be shape-set by heating to an annealing temperature whileconstrained to a shape, and then cooling. For example, a helix may beformed from a straight TiNi wire by winding the wire on a mandrel,securing the ends, heating to 550° C., and cooling. The rates of heatingand cooling are not critical in this ‘shape-setting’ process for TiNi,although special characteristics are achieved by holding the temperatureconstant at specific temperatures.

It is a general object of the invention to provide methods for the shapesetting fabrication of single crystal shape memory alloys (also called“hyperelastic”), such as CuAlNi, CuAlMn, CuAlBe, CuAlNb and others, andto provide devices made by such methods.

A further object of this invention is to provide new and improveddevices made of hyperelastic single crystal SMA by novel methods ofshape-setting.

In particular, it is the object of the invention to provide new andimproved SMA wires which may be used for orthodontic archwires.

In orthodontics, a standard procedure to correct malocclusions is toattach individual teeth to a flexible component called an archwire.These archwires are generally of a simple curved shape as illustrated inthe FIG. 3. Examples of stainless steel and titanium-nickel dentalarches are described and illustrated on the website ORMCO.com. Dentalarches are commonly made of wire of round or rectangular cross-section.Round wires range in wire diameter from 0.013 to 0.026 inches, whilerectangular cross-section arches may be as small as 0.016 by 0.016inches or a large as 0.020 by 0.030 inches.

Millions of orthodontic archwires are sold in the U.S. each year.Titanium-nickel-based alloys have taken market share because they haveelasticity superior to that of stainless steel. Increased elasticityenables the orthodontist to move teeth to their desired position withfewer adjustments and fewer replacements of the archwire.

A useful application of hyperelastic wire is in dental arches. Forexample, archwires made of hyperelastic alloy may have four importantadvantages over TiNi-based wires: (1) recoverable strain is increasedfrom 3-5 percent to 9-12 percent; (2) force exerted by a hyperelasticwire is less than the force exerted by a TiNi wire of comparablethickness; (3) the force is constant over a displacement of 9 percentstrain; and (4) the return force is nearly equal to the displacing forcebecause the mechanical hysteresis is very small. Because of theseadvantages, hyperelastic archwires may potentially replacetitanium-nickel-based archwires in a large percentage of orthodonticprocedures. At least one archwire manufacturer has been seeking a newmaterial with these advantages. Unfortunately, typical methods offabricating such wires may not work for the fabrication of hyperelasticmaterials.

For convenience of use, straight wires are typically formed into an archshape that approximately conforms to the shape of the jaw of thepatient, a process known as shape-setting. TiNi based alloy wires areshape-set by winding on a mandrel having the desired arch shape,annealing by heating in a furnace to 500° C. or higher, and allowing theshaped wires to cool. This shape-setting process may take an hour ormore.

The process described for shape-setting TiNi based wire cannot be usedfor shape-setting hyperelastic wire. Hyperelastic wire, typically singlecrystal, is not thermodynamically stable. At elevated temperatures ofseveral hundred degrees, one or more of the components (especially Al)gradually forms precipitates. These precipitates remove the element fromthe crystal lattice, effectively changing the composition and hence thetransition temperature of the alloy. A wire heated to 500° C. and cooledover a period of several minutes has no shape memory and nosuperelasticity.

This property, the precipitation of Al at high temperature, can beavoided if the wire is heated and cooled rapidly, for example in a fewseconds. It is impractical to quickly heat and cool a mandrel of masssufficient to impart the desired shape. This has led us to the inventionof a novel process for shape-setting hyperelastic wires for orthodonticarches, as described herein.

The present invention accomplishes, using a novel method, the purpose ofimparting an arch shape to a straight hyperelastic wire while preservingits elasticity and transition temperature.

SUMMARY OF THE INVENTION

The present invention relates to methods for shape setting hyperelasticmaterials, such as single-crystal Cu-based shape memory alloys (SMAs).In particular, the methods described herein include methods of forminghyperelastic materials in to dental appliances, including dentalarchwires.

For example, described herein are methods of shape-setting a wire ofsingle-crystal shape memory alloy into an arched wire shape whilemaintaining its integrity as a single crystal shape memory alloy. Themethod may include the steps of: heating the wire to a first temperaturesufficient for annealing the alloy; forcing the wire into an archedshape while the wire is held at the first temperature, wherein theheating and forcing steps are performed in less than 10 seconds; andrapidly cooling the alloy to room temperature sufficiently quickly tocause the alloy to form a single-crystal. In some variations, thesemethods may also include the steps of pulling the single crystal wire.

The step of heating the wire may be performed for less than 1 second orfor up to about 10 seconds. The step of rapid cooling is performed forless than about 0.5 second. For example, the steps of heating, forcingand cooling may all be performed in less than about 5 seconds, less thanabout 2 seconds, or less than about 1 second.

In some variations, the step of forcing the wire into an arched shapecomprises rapidly contacting the heated wire with a mandrel. The mandrelmay be a copper or stainless steel mandrel, as mentioned. The step offorcing the wire into an arched shape may include dropping the mandrelagainst the heated wire. For example, the step of forcing the wire intoan arched shape may include bringing the mandrel rapidly into contactwith the heated wire and allowing the mandrel with the wire) to dropinto a quenching bath. Thus, the step of rapidly cooling the wire maycomprise dropping the heated wire and mandrel into a cooling bath.

The step of forcing the wire into an arched shape may comprise forcingthe wire into a dental arch shape having a round diameter of betweenabout 0.013 to about 0.026 inches. In some variations, the step offorcing the wire into an arched shape comprises forcing the wire into adental arch shape having rectangular dimensions of between about 0.016by 0.016 inches and about 0.020 by 0.030 inches.

Also described herein are methods of shape-setting a wire ofsingle-crystal alloy into a dental arch so that it is comprised of asingle-crystal shape memory alloy. The method may include the steps of:heating the wire to an annealing temperature sufficient for annealingthe alloy; forcing the heated wire into a dental arch shape by forcingthe wire against a mandrel, wherein the steps of heating and forcing thewire against the mandrel are performed in less than 10 seconds; andrapidly cooling the wire by quenching to a cooling temperaturesufficiently quickly to cause the alloy to remain a single-crystal inthe dental arch shape.

Also described herein are methods of shape-setting an alloy into adental arch so that it is comprised of a single-crystal CuAlNi shapememory alloy, the method comprising the steps of: heating a wire ofCuAlNi alloy to a first temperature sufficient to place the Cu, Al andNi in solution; rapidly quenching the alloy to a second temperature toprevent precipitation of the Cu, Al and Ni so that the alloy remains asa single-crystal of CuAlNi; constraining the alloy into a dental archshape; heating the alloy to a third temperature for a first time period,wherein the third temperature and first time period are sufficient tocause the alloy to lose its strength; and cooling the alloy to a fourthtemperature for a second time period, wherein the fourth temperature andsecond time period are sufficient to cause the alloy to remain asingle-crystal in the shape.

Dental arches formed by any of the methods discussed herein are alsodescribed. Thus, described herein are dental arches comprising ahyperelastic, single-crystal shape memory material. The dental archtypically has an elongate, curved length that is configured to fitwithin a human mouth. For example the dental arch may traverse an arcextending approximately 180 degrees in an unstressed state (at rest). Insome variations, the dental arch formed of the single crystal shapememory alloy material has a curved elongate length with a round diameterof between about 0.013 to about 0.026 inches. In other variations thedental arch has a curved elongate length with a rectangularcross-section with dimensions of between about 0.016 by 0.016 inches andabout 0.020 by 0.030 inches.

As mentioned above, the dental arch may be formed of a single-crystalshape memory alloy of CuAlNi single crystal material. Othersingle-crystal shape memory alloys may be used, including: CuAlMb singlecrystal material; CuAlMn single crystal material, CuAlBe single crystalmaterial, and CuAlNb single crystal material in some variations,four-component alloys may be used. In some variations, specialcharacteristics such as increased ductility may be achieved bysubstituting all or part of the Ni of CuAlNi with Mn, Fe, Be etc: or bya combination of one or more of these elements. For example, the dentalarches described herein may be formed of CuAlNiMn (e.g., single-crystalCuAlNiMb), using the processes and techniques detailed below.

One advantage of the methods for fabricating the single-crystal shapememory alloy dental archwire devices as described herein is that theintegrity of the single crystal material forming the final dentalarchwire is intact when the device is completely formed, and little (ifany) post-processing is necessary. The single crystal dental archwiresdescribed herein have many advantages, particularly in physicalproperties, compared to even polycrystalline archwires formed of thesame materials (e.g. CuAlNi).

In some variations the dental arch has different regions along thelength of the dental arch that have different material properties. Forexample, the ends of the dental arch wire may be in the martensiticphase at body temperature. During formation of the dental arch wire, theends may be cooled slowly, so that they are in the martensite phase.

Apparatuses and systems for forming a single-crystal shape memory archwire are also described herein. In general, these devices and systemsare configured to form a wire (including a wire of single-crystal shapememory material) into a dental arch while preserving the single-crystalnature of the wire.

For example, described herein are apparatuses for forming a wire ofshape memory alloy into a dental arch while preserving thesingle-crystal nature of the wire that include: a power source forheating the wire to above an annealing temperature of the shape memoryalloy; a holder for holding the ends of the wire so that the wire may beheated by the power source; a mandrel for shaping the wire; a driver fordriving the mandrel against the heated wire held by the holder; and aquenching sub-assembly for rapidly quenching the wire connected to themandrel to room temperature within less than about 1 second.

Any appropriate power source may be used. For example, in somevariations the power source is an electrical power supply configured toapply power to the wire to heat the wire to a temperature above theannealing temperature of the shape memory alloy forming the wire. Insome variations, the power source is a variable voltage source.

In general, the power source is configured to heat the wire to atemperature around or above the annealing temperature of the shapememory allow. The power source may hold the wire at this temperaturee.g., greater than 600 degrees in sonic variations) while waiting forthe mandrel to be driven against the wire, before quenching the wire.

The holder may be any holder that is configured to secure the wirewithin the apparatus so that the wire can be heating above the annealingtemperature and then very quickly quenched by the quenchingsub-assembly. For example, the holder may include a pair of clamps orgraspers. In some variations these graspers are configured toelectrically connect the wire to the power source. The clamps orgraspers may be configured to secure the wire but allow it to bedisplaced into the quenching sub-assembly. For example, the clamps mayloosely hold the wire or be extendable/releasable to allow the wire tobe dropped or driven into the quenching sub-assembly by the mandreland/or driver (e.g., a plunger).

The mandrel typically comprises an arced shape configured to form adental arch. For example, the mandrel may be a metal or ceramic materialthat is shaped into an arch conforming to the dimensions of a dentalarch to be formed. The mandrel may include a guide region to bendagainst the wire and shape it.

In some variations the mandrel is connected to a driver and isconfigured to drop against the wire (which may be secured by theholder), forming the wire into the shape of the dental arch, anddropping the wire into the quenching sub-assembly. For example, thedriver may comprise a plunger.

A quenching sub-assembly is generally configured to cool the wire to anappropriate temperature. For example, the quenching sub-assembly may bea bath configured to hold salt water. The bath may be cooled (e.g., toroom temperature or lower).

For example, described herein are apparatuses for forming a wire ofshape memory alloy into a dental arch while preserving thesingle-crystal nature of the wire, the apparatus comprising: a voltagesource for heating the wire to above an annealing temperature of theshape memory alloy; a pair of conductive holders for holding the ends ofthe wire in electrical communication with the voltage source so that thewire can be heated by the power source; a curved mandrel for shaping thewire; a plunger above the mandrel for driving the mandrel against theheated wire held by the holder; and a quenching sub-assembly comprisinga bath positioned below the mandrel and plunger and configured toreceive the mandrel and wire to rapidly quench the wire to roomtemperature within less than about 1 second.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevation view showing a hyperelastic wire superimposedover a steel mold used to form the wire.

FIG. 2 is a phase diagram of CuAlNi in which the Ni is 3 weight %.

FIG. 3A shows prior art orthodontic archwires for an upper and a lowerjaw. It consists of a titanium-nickel wire, 0.016 inches in diameter,formed into an arch. The archwire form is approximately three incheshigh and three inches wide. The upper and lower archwires may beslightly different shapes. The single crystal archwires described hereinmay have a similar overall shape, though they may have superiorproperties resulting from their single crystal nature.

FIG. 3B shows another variation of a prior art dental archwire, referredto as a reverse-curve archwire. Such archwires may include curves inmultiple directions.

FIG. 4 illustrates one variation of an apparatus for shape-setting ahyperelastic material into an archwire.

DETAILED DESCRIPTION OF THE INVENTION

Hyperelastic alloys formed as single crystals, for example, CuAlNisingle crystals of approximately Cu(84)Al(14)Ni(4) wt. %, have enhancedstrain recovery properties compared to more conventional polycrystalSMAs such as Nitinol. Such single crystals are formed as extruded shapeswhether by pulling from melt or by continuous casting. It is desirableto form other shapes such as helices or bends, but the methodology usedfor forming Nitinol destroys the single crystallinity; a problem withpolycrystal CuAlNi is that it is brittle. Therefore there is a need formethods which avoid these and other problems.

The fabrication and performance of such single crystal SMA materials aredisclosed in U.S. application Ser. No. 10/588,412 filed Jul. 31, 2006,the disclosure of which is incorporated by this reference.

If single-crystal CuAlNi is drawn from melt and cooled by use of theStepanov method, as the single crystal cools, precipitates form so thatstrength, shape memory, and hyperelastic properties are not optimal.Imparting shape memory and hyperelastic properties requires heating to atemperature high enough to dissolve the precipitates, followedimmediately by rapid cooling (“quenching”) to lock in the dissolvedelemental components. Methods used for producing single crystal shapememory alloys generally produce net shapes in the crystal. FIG. 2 showsthe phase diagram of CuAlNi in which the Ni is 3 weight %. Singlecrystal devices of other shape memory alloys may be formed using themethods described herein, including CuAlMn, CuAlBe, etc.

Use of elevated temperature to modify the shape of hyperelastic singlecrystal of alloys such as CuAlNi (e.g., CuAlMn, CuAlBe, etc.) normallyresults in loss of single crystallinity: at elevated temperaturesprecipitation of elemental components (especially Al) changes thecomposition. For this reason actuators and flexures designed to exploitthe extraordinary strain recovery of these materials (9% strain) havebeen limited to net shapes solid and tubular cylinders) produced duringformation of the crystal. However, if heating and quenching take placein a very short time (fraction of a second) the precipitation does notprogress far enough to cause significant change in the composition andthe hyperelastic properties can be retained. These discoveries by thepresent inventors enable a variety of methods for shape-setting singlecrystal SMAs. Extruded shapes may be bent, elongated with reduction ofdiameter, and tubular as well as solid crystal shapes may be re-formed.These novel methods extend the usefulness of single crystal SMA byremoving a limitation on shapes.

Single crystals pulled from melt have an as-formed or extruded shapesuch as a solid or hollow cylindrical shape with a constantcross-sectional form. It is sometimes advantageous to alter thefabricated shape into a shape more suited to a particular application.One such application is for use as eyeglass frame hinge flexures toreplace hinges or to replace the entire eyeglass frame. Another is toform curves in a guidewire to follow tortuous paths in a blood vessel,or a sieve placed in a blood vessel for the purpose of retrieving andremoving a blood clot. Another form is the dental archwire mentionedabove. The various embodiments of the present invention provideprocesses for “shape-setting” CuAlNi, CuAlMn, CuAlBe, or othersingle-crystal materials.

For example, CuAlNi single crystal is in a metastable condition andgradually deteriorates to polycrystalline form. The rate ofdecomposition is temperature dependent. At room temperature the rate issufficiently low that negligible change takes place over years. At300-400° C., the rate is rapid enough that degeneration to multiplecrystals may occur in a few seconds. Once formed, the multiple crystalsdo not re-form as a single crystal: this requires melting and specialprocessing. However, CuAlNi may retain its single crystal conditionthrough repeated heating to annealing temperature and rapid cooling. Atsufficiently high temperature (typically 850-950° C.) the threecomponents Cu, Al, and Ni are in solution, CuAlNi's hyperelasticproperties are exhibited within a very narrow range of compositions. Ifcooling is not sufficiently rapid, Al precipitates from the solution,changing the composition and drastically altering thermo-mechanicalproperties.

The crucial insight leading to the present invention is that acombination of annealing, constrained shaping, and quenching leads to analtered “remembered” shape.

Quenching, that is rapidly lowering the temperature from a temperatureat which the three components Cu, Al, and Ni are in solution, isconventionally used to “freeze in” the composition by not permittingelemental components from forming precipitates. If cooling takes placeslowly these precipitates remove atoms from the crystal lattice andmodify it in such a way as to destroy the phase transformation thatleads to the shape memory effect. Rapid cooling preserves the integrityof the solution.

Composition can be altered during heating and cooling cycles by the factthat Al at the surface forms aluminum oxide, and the oxide, beinginsoluble, is effectively removed from the material. Reducing the Alcontent by 0.1%, which increases the phase transformation temperature,may alter the transition point enough to make the material useless,

It is a common characteristic of metals that there is a temperaturerange below the melting point within which internal stresses areminimal. Such an ‘annealed’ material can be deformed far beyond itsnatural limits without breaking, and the deformed shape is retainedafter cooling.

For example, the annealing temperature of CuAlNi single crystal alloy isabout 600° C. When heated to this temperature its shape may bedrastically changed with very small applied forces. When cooled, thematerial retains the modified shape, and if it is rapidly cooled it alsoretains its shape memory qualities.

To shape-set a portion of elongated component of CuAlNi for CuAlMn,CuAlBe, etc.), it is important that heating and cooling both be veryrapid. Otherwise the material in the heat-affected zone adjacent to theheated portion may undergo precipitation, resulting in an alteredcomposition, or it may form multiple crystals because of criticalstress. Polycrystalline alloys have far less strain tolerance andrecovery, so are much inferior in performance compared to singlecrystals.

If the objective is to make a bend in, for example, a wire, then it isnecessary either to heat all of the wire uniformly or the heating andcooling must be done quickly.

Otherwise the wire in the heat-affected zone between the heated segmentand the un-heated segment will be held at an intermediate temperature,above ambient but below the annealing temperature. In this intermediatetemperature range the single crystal (e.g., CuAlNi single crystal) isunstable and will degenerate rapidly to polycrystal form and be quitebrittle.

Rapid cooling may be satisfactorily performed by submersion in saltwater. Rapid heating is not as readily accomplished. Several methods aredemonstrable: each has advantages and disadvantages.

Rapid heating can be accomplished by immersing the object to beshape-set in a very hot flame such as provided by an oxy-acetylenetorch. The sample is held in the flame while it transforms and becomesstraight, begins to glow, and then anneals. The sample is then quicklyremoved from the flame and, while constrained in the desired shape, itis plunged into salt water. Salt water is used because a layer ofbubbles does not form to insulate the surface of the material.

Another method is to constrain the shape of the wire to the desiredshape in a mold, heat the mold, and quench. Quench must be relativelyfast, but in this case the specimen may be held at an elevatedtemperature (850-950° C.) for as long as is convenient.

For example, a CuAlNi wire is inserted in a stainless steel tube. Thetube is heated to its annealing temperature (about 850° C.) and shapedby bending. Several bends may be incorporated. After bending, the tubeis uniformly heated in an oven to 650-750° C. to anneal the CuAlNi, andthen quickly quenched. The CuAlNi wire when removed from the stainlesssteel tube retains the modified shape: it has been shape-set.

A variation of this method is first to form a stainless steel tube intothe shape desired, for example by heating segments in an acetylene flameand bending. After the tube is formed the CuAlNi wire is inserted intoit at room temperature, and the tube with wire inside are heated andquenched. In this case it is important not to deform the CuAlNi too muchas it may form multiple crystals. Re-crystallization occurs rapidly ifCuAlNi is overstressed.

CuAlNi contained within a stainless steel tube is not ideal for rapidcooling. Cooling rate may be significantly enhanced by forming a numberof holes in the tube to allow contact with the water and to reduce theinsulating effect of air trapped within the tube.

Samples of hyperelastic CuAlNi heated to 950° C. In stainless steel tubeand cooled by immersion in salt water have been found to be martensiticalthough shape-setting has taken place. The transition temperature maybe reduced by re-heating the sample without the stainless steel mold andquenching it bare.

If deformation takes place prior to heating, strain must be limited tothe plateau, about 9%, so as not to re-crystallize. If the sample isheated to near melting, then deformed and quenched, much largerdeformations are tolerated.

In this example, stainless steel is used to constrain the deformedhyperelastic wire because the annealing temperature of stainless steelis higher than the temperature at which CuAlNi softens and becomeseasily deformed. During heating, as the plateau stress of thehyperelastic material increases, the hyperelastic material exerts agreat force. If a copper tube is used, its walls must be thick comparedto the diameter of the hyperelastic. Otherwise, the force of thehyperelastic material shape recovery may cause the Cu tube to(partially) straighten because Cu anneals at a temperature lower thanthe softening temperature of hyperelastic material.

Another method is to heat the material by a laser beam or by an infraredheater. The beam may be moved onto the sample or vice versa. Thetechnique works better if two beams are used, one on each surface.Quenching may be by spraying or dousing with salt water or other heatabsorber.

Another method of rapid heating is by joule heating. A pulse ofelectrical energy is directed such that it is dissipated in thematerial, heating it to near incandescence. If heating is very rapid thematerial may be immersed during the heating phase, so that at the end ofthe joule heating pulse it immediately cools. Otherwise the sample maybe moved so that it is immersed, or doused or sprayed with cold liquid.

The joule heating method is not limited to materials of small diameter.However, it is difficult to deliver the electrical energy into the SMA(e.g., CuAlNi, CuAlMn, CuAlBe, etc.) as they are typically very goodelectrical conductors (resistivity is of the order of 30 microhm*cm.Pure copper is 1.5 microhm*cm.)

Still another method of heating is by induction heating.

These methods work best on material samples that are small in onedimension such as thin foils or fine wires.

Example of One Embodiment

A 1 mm diameter CuAlNi straight hyperelastic wire having a transitiontemperature at +10° C. was held in a curved shape with two pairs ofpliers while being placed in an oxy-acetylene flame for approximately 3seconds. The wire stiffened and straightened as it was heated, thensoftened and bent to a radius of about 5 mm. It was rapidly cooled byimmersion in a pan of room-temperature salt water. After this procedurethe wire retained a curvature of about 5 mm under no external stress,and returned to this shape after being straightened. This degree ofcurvature corresponds to a strain of approximately 10%, which comparesfavorably with the hyperelastic properties of the untreated wire, butwith an altered shape.

Device Embodiments of the Invention

One application is as a flexure to replace hinges in eyeglasses. A stripof CuAlNi may be shape-set so that it is bent at a right angle. One endis attached to the frame; the other is attached to the temple piece ofthe glasses. A cam or eccentric may be included to provide two stablepositions: with the glasses worn on the face, or with the glasses foldedfor transport or storage. Alternatively the entire glasses frame may befabricated of CuAlNi single crystal wire by appropriate shape-setting.

As shown in FIG. 1, a hyperelastic wire 10 can be made in the desiredshape by forming with the steps described above the wire within atubular steel mold 12 which generally conforms to the wire shape.

EXAMPLE Dental Arches

In this example, a dental archwire may be formed from a single-crystalSMA material CuAlNi). The wire is heated by Joule heating, either as anelectrical pulse or as a continuous electrical current, AC or DC, toannealing temperature. Typical currents are from 10 to 30 amperes.Voltage applied to the wire ends is typically 1 to 3 volts.

While it is at annealing temperature, the wire is quickly (less than 0.5seconds) wrapped about a mandrel having the desired arch shape, and thenplunged into a quenching bath. The sequence of heating, forcing theshape, and cooling may take less than a second.

In a first exemplary embodiment, an apparatus is used that consists of avariable voltage transformer, clamps or tubes that hold the wire ends incontact with the output (low-voltage) electrodes of the transformer, anda plunger with a U-shaped concavo-convex metal (copper) mandrel. Thisapparatus is illustrated in FIG. 4.

In FIG. 4, the apparatus for shape-setting hyperelastic wires is shownand includes a Variac whose control knob is seen at the left side of thefigure. The Variac supplies a stepped down voltage to the powertransformer at center right in the figure. This transformer furthersteps down the AC voltage to a range of 1-3 volts, supplying a currentof 10-40 amperes to the electrodes. These electrodes are two brass bars,suspended on a translucent plastic frame, extending from the powertransformer electrical terminals to the hyperelastic wire. A portion ofthe hyperelastic wire may be seen below the forming mandrel, a U-shapedmetal trough with flanges extending outward. The mandrel is preventedfrom falling onto the wire by a rod attached at the center of the U,extending through the translucent plastic frame and held temporarily bya clamp.

In operation, the process consists of heating the wire by current fromthe electrodes until it is annealed (greater than about 600° C.), thenreleasing (un-clamping) the forming mandrel with attached rod so that itfalls onto the wire, forming the wire about the mandrel, disconnectingit from the electrodes, and forcing it into the vessel of quenchingwater. The heating process can be accomplished in less than 5 seconds:quenching takes place in a few milliseconds.

As mentioned, the mandrel may be suspended above the wire until the wireis heated to the desired temperature. Then the mandrel is released sothat it falls by gravity against the heated wire. The force exerted onthe wire by the mandrel as it falls pulls the wires from the clamps ortubes: this pulling force ensures that the wire is constrained to alignwith the inner groove shape of the mandrel. The mandrel immediatelybegins to absorb heat from the wire by contact, and then both themandrel and the wire are quickly cooled by immersion in a water bath.

In this example, the mandrel is made of a single sheet of copper,thickness 0.005-0.020 inches, approximately 7 inches long and 0.5 incheswide. This sheet is folded along its long axis while being bent alongthe apex into a desired U shape with the edges pointed outward from thefold. This complex bend can be accomplished by lightly hammering thefolded copper sheet into the desired U shape, with repeated annealing ata high enough temperature that the copper does not become work hardened.This technique is well known to metal art workers.

This method of shape-setting is applicable to any wire that it isdesired to form into a simple curve, such as titanium-nickel basedalloys that are commonly used for archwires.

In some variations, the wire forming the dental arch may have propertiesthat vary along the length of the wire. For example, the dental arch maybe formed and heat treated to give different regions or lengths of thedental arch different properties. For example, the properties of CuAlNi(and other shape memory alloys) enable another useful modification ofdental arches well as other applications. The additional properties mayarise because different segments of the wire may be differently heattreated, thereby imparting different properties along its length. Indental arches this might be very useful: for example, the dental archmay be configured so that one part of the wire might pull on a toothwith a stronger force than another, or provide different rotationparameters for different teeth. Also, orthodontists are accustomed tomaking a sharp bend at the end of the wire to fix it in place. If theend of the wire is heated to annealing temperature and allowed to coolslowly, it will be in the martensite phase and hence will remain crookedrather than springing back after it is bent. This characteristic mightbe a desirable feature also for making it easier to load (or thread) thewire into the brackets that are attached to the teeth.

While particular forms of the invention have been illustrated anddescribed herein, it will be apparent that various modifications andimprovements can be made to the invention. Moreover, individual featuresof embodiments of the invention may be shown in some examples and not inothers, but those skilled in the art will recognize that individualfeatures of one embodiment of the invention can be combined with any orall the features of another embodiment. Accordingly, it is not intendedthat the invention be limited to the specific embodiments illustrated.It is intended that this invention to be defined by the scope of theappended claims as broadly as the prior art will permit.

1. A method of shape-setting a wire of single-crystal shape memory alloyinto an arched wire shape so that it is comprised of a single-crystalshape memory alloy, the method comprising the steps of: heating the wireto a first temperature sufficient for annealing the alloy; forcing thewire into an arched shape while the wire is held at the firsttemperature, wherein the heating and forcing steps are performed in lessthan 10 seconds; and rapidly cooling the alloy to room temperaturesufficiently quickly to cause the alloy to form a single-crystal.
 2. Themethod of claim 1, wherein the steps of heating and forcing the wire areperformed for less than 1 second before the cooling step.
 3. The methodof claim 1, wherein the step of rapidly cooling comprises cooling thewire to room temperature from the first temperature in less than about0.5 second.
 4. The method of claim 1, wherein the steps of heating,forcing and cooling are all performed in less than about 5 seconds. 5.The method of claim 1, wherein the step of forcing the wire into anarched shape comprises rapidly contacting the heated wire with amandrel.
 6. The method of claim 5, wherein the step of forcing the wireinto an arched shape comprises dropping the mandrel against the heatedwire.
 7. The method of claim 6, wherein the step of rapidly cooling thewire comprises dropping the heated wire and mandrel into a cooling bath.8. The method of claim 1, wherein the step of forcing the wire into anarched shape comprises forcing the wire into a dental arch shape havinga round diameter of between about 0.013 to about 0.026 inches.
 9. Themethod of claim 1, wherein the step of forcing the wire into an archedshape comprises forcing the wire into a dental arch shape havingrectangular dimensions of between about 0.016 by 0.016 inches and about0.020 by 0.030 inches.
 10. A method of shape-setting a wire ofsingle-crystal alloy into a dental arch so that it is comprised of asingle-crystal shape memory alloy, the method comprising the steps of:heating the wire to an annealing temperature sufficient for annealingthe alloy; forcing the heated wire into a dental arch shape by forcingthe wire against a mandrel, wherein the steps of heating and forcing thewire against the mandrel are performed in less than 10 seconds; andrapidly cooling the wire by quenching to a cooling temperaturesufficiently quickly to cause the alloy to remain a single-crystal inthe dental arch shape.
 11. A method of shape-setting an alloy into adental arch so that it is comprised of a single-crystal CuAlNi shapememory alloy, the method comprising the steps of: heating a wire ofCuAlNi alloy to a first temperature sufficient to place the Cu, Al andNi in solution; rapidly quenching the alloy to a second temperature toprevent precipitation of the Cu, Al and Ni so that the alloy remains asa single-crystal of CuAlNi; constraining the alloy into a dental archshape; heating the alloy to a third temperature for a first time period,wherein the third temperature and first time period are sufficient tocause the alloy to lose its strength; and cooling the alloy to a fourthtemperature for a second time period, wherein the fourth temperature andsecond time period are sufficient to cause the alloy to remain asingle-crystal in the shape.
 12. A dental arch formed by the method ofclaim
 1. 13. A dental arch formed by the method of claim
 10. 14. Adental arch formed by the method of claim
 11. 15. A dental archcomprising a hyperelastic, single-crystal shape memory material, thedental arch having an elongate, curved length that is configured to fitwithin a human mouth.
 16. The dental arch of claim 15, wherein thecurved elongate length has a round diameter of between about 0.013 toabout 0.026 inches.
 17. The dental arch of claim 15, wherein the curvedelongate length has a rectangular cross-section with dimensions ofbetween about 0.016 by 0.016 inches and about 0.020 by 0.030 inches. 18.The dental arch of claim 15, wherein the single-crystal shape memoryalloy comprises a CuAlNi single crystal material.
 19. The dental arch ofclaim 15, wherein the single-crystal shape memory alloy is selected fromthe group consisting of CuAlMb single crystal material; CuAlMn singlecrystal material, CuAlBe single crystal material, and CuAlNb singlecrystal material.
 20. The dental arch of claim 15, wherein differentregions along the length of the dental arch have different materialproperties.
 21. The dental arch of claim 15, wherein the ends of thedental arch wire are in the martensitie phase at body temperature. 22.An apparatus for forming a wire of shape memory alloy into a dental archwhile preserving the single-crystal nature of the wire, the apparatuscomprising: a power source for heating the wire to above an annealingtemperature of the shape memory alloy; a holder for holding the ends ofthe wire so that the wire may be heated by the power source; a mandrelfor shaping the wire; a driver for driving the mandrel against theheated wire held by the holder; and a quenching sub-assembly for rapidlyquenching the wire connected to the mandrel to room temperature withinless than about 1 second.
 23. The apparatus of claim 22, wherein thepower source is an electrical power supply configured to apply power tothe wire to heat the wire to a temperature above the annealingtemperature of the shape memory alloy forming the wire.
 24. Theapparatus of claim 22, wherein the power source is a variable voltagesource.
 25. The apparatus of claim 22, wherein the power source isconfigured to heat the wire to a temperature of greater than 600degrees.
 26. The apparatus of claim 22, wherein the holder comprises apair of clamps configured to electrically connect the wire to the powersource.
 27. The apparatus of claim 22, wherein the mandrel comprises anarced shape configured to form a dental arch.
 28. The apparatus of claim22, wherein the mandrel is connected to the driver and configured todrop against the wire secured by the holder, dropping the wire into thequenching sub-assembly.
 29. The apparatus of claim 22, wherein thedriver comprises a plunger.
 30. The apparatus of claim 22, wherein thequenching sub-assembly comprises a bath configured to hold salt water.31. An apparatus for forming a wire of shape memory alloy into a dentalarch while preserving the single-crystal nature of the wire, theapparatus comprising: a voltage source for heating the wire to above anannealing temperature of the shape memory alloy; a pair of conductiveholders for holding the ends of the wire in electrical communicationwith the voltage source so that the wire can be heated by the powersource; a curved mandrel for shaping the wire; a plunger above themandrel for driving the mandrel against the heated wire held by theholder; and a quenching sub-assembly comprising a bath positioned belowthe mandrel and plunger and configured to receive the mandrel and wireto rapidly quench the wire to room temperature within less than about 1second.